Note: Descriptions are shown in the official language in which they were submitted.
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COMPACT STACKABLE TRAY
FIELD OF THE INVENTION
[0001] The present invention relates to a compact stackable tray. In
particular, the present application relates to a stackable tray which in a
first
orientation supports a like tray positioned above the tray and in a second
orientation nests with the like tray.
BACKGROUND
[0002] Traditionally, milk in bags is delivered to the merchant in crates
stacked on pallets or placed on a stainless steel rolling rack (bossy cart)
which can for example be pushed into a refrigerator and be merchandisable
without further intervention. The racks are heavy and expensive and lead to
injuries and the like. A picked pallet configuration where the pallet is
delivered
to the merchant preloaded and simply placed in racking and or on the ground
from which customers can select the product they wish to purchase is typically
preferred given its simplicity. However, current one way solutions which rely
on the use cardboard boxes or the like require robust materials which are
difficult to dispose of.
[0003] What is needed therefore, and an object of the present application
is an ecofriendly, inexpensive and convenient means to organize, transport
and display for sale milk or other beverages held in bags, cartons or jugs as
well as other items such as produce and the like.
[0004] An object of the present invention, therefore, is to provide a tray
and system that in turn minimises the need for secondary packaging, is retail
ready, reusable in a closed loop system and which is stackable and nestable
thereby minimizing the space required for empty container storage and return.
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,
SUMMARY OF THE INVENTION
[0005] In order to address the above and other drawbacks, there is
provided a compact stackable tray configured for stacking with other like
trays. The tray comprises a flat rectangular support, a plurality of dividers
integral to the support and separating an upper surface of the support into a
plurality of compartments, each of the compartments sized to receive a
bottom of at least one standard milk container therein, a rim about a
periphery
of the rectangular support, and a first pair of hollow uprights arranged
towards
a first short edge of the support and a second pair of hollow uprights
arranged
towards a second short edge of the support opposite the first edge, the
uprights extending above the support to a height above that of a standard milk
container when supported on the support. In a first orientation of the tray to
an
upper like tray, the upper like tray is supported by the uprights of the tray
and
such that a lower surface of a support of the upper tray is maintained at
least
a height of the standard milk container above an upper surface of the support
of the tray and wherein in a second orientation of the upper tray to the tray
rotated 180 degrees horizontally to the first orientation, the hollow uprights
of
the tray nest within the hollow uprights of the upper tray and such that the
lower surface of the support of the upper tray is immediately adjacent the
upper surface of the support of the tray when empty and further wherein the
uprights combined can support a minimum weight of 160kgs.
[0006] Additionally, there is provided a compact stackable tray
system
comprising a pair of like compact stackable trays arranged as an upper tray
and a lower tray, each of the trays comprising a flat rectangular support, a
plurality of dividers separating an upper surface of the support into a
plurality
of compartments, each of the compartments sized to receive at least one
standard milk container therein, a rim about a periphery of the rectangular
support, and a first pair of hollow uprights arranged along a first short edge
of
the support and a second pair of hollow uprights arranged on a second short
edge of the support opposite the first edge, the uprights extending above the
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support. In a first orientation of the upper tray to the lower tray, the upper
tray
is supported by the uprights of the lower tray such that a lower surface of
the
support of the upper tray is maintained at least a height of the standard milk
container above an upper surface of the support of the lower tray and wherein
in a second orientation of the upper tray to the lower tray rotated 180
degrees
horizontally to the first orientation, the hollow uprights of the lower tray
nest
within the hollow uprights of the upper tray and such that the lower surface
of
the support of the upper tray is immediately adjacent the upper surface of the
support of the lower tray and further wherein for each tray the uprights
combined can support a minimum weight of 160kgs.
[0007] Also
there is provided a compact stackable tray system for stacking
milk containers of a plurality of different milk container formats. For a
given
one of the plurality of standard milk container formats, at least one compact
stackable tray is provided comprising a flat rectangular support, a plurality
of
dividers separating an upper surface of the support into a plurality of
compartments, each of the compartments sized to receive at least one
standard milk container of the given standard milk container format therein,a
rim about a periphery of the rectangular support, and a first pair of hollow
uprights arranged along a first short edge of the support and a second pair of
hollow uprights arranged on a second short edge of the support opposite the
first edge, the uprights extending above the support. In a first orientation,
an
upper tray is supported by uprights of a lower tray such that a lower surface
of
a support of the upper tray is maintained at least a height of the given
standard milk container of the lower tray above an upper surface of the
support of the lower tray and wherein in a second orientation of the upper
tray
to the lower tray rotated 180 degrees horizontally to the first orientation,
if the
upper tray and the lower tray are each adapted for stacking a like given milk
container format, the hollow uprights of the lower tray nest within the hollow
uprights of the upper tray and such that the lower surface of the support of
the
upper tray is immediately adjacent the upper surface of the support of the
lower tray, and if the upper tray and the lower tray are each adapted for
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,
stacking a different given milk container format, the hollow uprights of the
lower tray are unable to nest within the hollow uprights of the upper tray,
and
further wherein for each tray the uprights combined can support a minimum
weight of 160kgs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Figure 1 provides an isometric view of a pair of compact
stackable
trays in accordance with an illustrative embodiment of the present invention,
[0009] Figure 2A provides a sectional view of a pair of compact
stackable
trays along lines 11A-IIA in Figure 1;
[0010] Figure 2B provides a front plan view of a compact stackable
tray in
accordance with an illustrative embodiment of the present invention;
[0011] Figure 2C provides a detailed side view of an upright of a
lower tray
nested in an upright of an upper tray and in accordance with an illustrative
embodiment of the present invention;
[0012] Figure 2D provides a top plan view of a compact stackable
tray in
accordance with an illustrative embodiment of the present invention;
[0013] Figure 3 provides a lowered right front view of a pair of
compact
stackable trays in accordance with an illustrative embodiment of the present
invention;
[0014] Figure 4A provides a raised left front view of a plurality of
compact
stackable trays in a supported stack in accordance with an illustrative
embodiment of the present invention;
[0015] Figure 4B provides a raised left front view of a plurality of
compact
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stackable trays in a nested compact stack in accordance with an illustrative
embodiment of the present invention;
[0016] Figures 40 and 4D provided raised right front views of compact
stackable trays in a nested compact stack in accordance with an alternative
illustrative embodiment of the present invention;
[0017] Figure 4E provides a raised right front view of a compact stackable
tray in accordance with an additional alternative illustrative embodiment of
the
present invention;
[0018] Figure 4F provides a raised right front view of a stack of compact
stackable trays each configured for stacking a different standard milk
container format in accordance with an illustrative embodiment of the present
invention; and
[0019] Figure 5 is a raised left front view of a compact stackable tray in
accordance with an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0020] Referring now to Figure 1, a pair of compact stackable trays in
accordance with an illustrative embodiment of the present invention will now
be described. Each tray, generally referred to using the reference numeral 10,
is illustratively manufactured from injection molded plastic and comprises a
substantially flat molded plastic tray support 12 divided into a plurality of
bag
receiving compartments as in 14 by a series of dividers as in 16 aligned with
a
long edge of the tray 10. Each of the compartments as in 14 may be divided
into a pair of subcompartments 18 by provision of an additional divider 20
arranged across a respective compartment as in 14. A first pair of uprights as
in 22 is arranged along a first short edge 24 of the tray 10 and a second pair
uprights supports as in 26 is arranged along a second short edge 28 of the
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tray 10. As will be discussed in more detailed below an outer edge 30 of each
of the first pair of uprights as in 22 is positioned substantially flush with
a
respective long edge 32, 34 of the tray 10 while the second pair of uprights
as
in 26 are positioned away from their respective long edges 32, 34. The
dividers as in 16, 20 also provide structural strength to the tray support 12.
This allows heavier goods (not shown) to be supported by the support 12
and/or the support 12 to be manufactured from a thinner plastic without the
support 12 bending under the weight of those goods.
[0021] Still referring to Figure 1, in the illustrative embodiment each sub
compartment as in 18 is sized to accept a conventional milk bag (not shown).
As known in the art, such bags each comprise four (4) liters of milk or liquid
beverage organized in three (3) smaller bags of 1.33 liters each. Such bags
have minimal structural strength and will typically fall over if not
supported.
The dividers as in 16 are of between 5 and 8 centimeters height to provide
some support to the bags and help to maintain them in position and therefore
keeping a side of the bag clearly visible, while at the same time being low
enough to allow the milk bags to be individually extracted from the tray 10
without undue effort. A rounded upper edge 36 is also provided to the dividers
as in 16 to prevent snagging or tearing of the bags during extraction. Each
tray 10 also comprises a raised outer rim 38 of about 8 to 12 centimeters,
also
comprising a rounded upper edge, which provides additional support for bags
when the tray 10 is full thereby preventing bags retained within the tray from
inadvertently being ejected during transport, for example. In a particular
embodiment small drainage holes (no shown) may be provided in each sub
compartment as in 18 to allow for water or other liquids to escape, thereby
facilitating washing, for example.
[0022] Still referring to Figure 1, each upright as in 22, 26 extends
approximately 28 centimeters (11 inches) above the bottom of the tray 10 in
order, as will be discussed in more detail below, to provide adequate
clearance between stacked trays such that a standard milk bag in between
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may be freely removed.
[0023] Referring to Figures 2A and 2B, each of the uprights as in 22, 26 are
hollow and illustratively of a rectangular frustum shape and are of the same
height (i.e. they extend the same distance above the tray). The outer surfaces
as in 40 and the inner surfaces as in 42 of the uprights as in 22, 26 are
tapered such that, as will be discussed in more detail below, trays as in 10
may be compactly stacked together by inserting respectively the first uprights
22 and second uprights 26 of a lower tray inside the hollow first uprights 22
and hollow second uprights 26 of an upper tray. In this regard, small holes
(not shown) may be provided in the apex 48 of each upright as in 22, 26 to
allow air to escape and enter the hollow support during compact nested
stacking. Additionally, and with reference to Figure 2C, the taper of the
outer
surface 40 and the inner surface 42 of the uprights as in 22, 26 is selected
such that during compact stacking, the outer surface 40' of the uprights as in
22, 26 of a lower tray remain a small distance "d" apart from the inner
surfaces 42' of the uprights as in 22, 26 of the upper tray, or in other words
the uprights as in 22, 26 do not bottom out in a compact stacked
configuration. This limits sticking, for example when the trays as in 10 are
wet
or the like allowing for easy unstacking of a compact stack of trays.
[0024] Referring to Figure 2D, each of the trays is rectangular in shape and
illustratively 24 inches X 20 inches such that four (4) trays as in 10 may be
placed in a 2 X 2 configuration to match the 40 inch by 48 inch foot print of
a
standard commercial pallet (not shown) and such that when positioned in a
rack or the like one of the long edges 32, 34 of each tray, and therefore the
individual milk bags, is displayed towards the front of the pallet, thereby
allowing the product to be quickly recognized. Additionally, the uprights as
in
22, 26 are dimensioned such that five (5) loaded and inverted trays may be
stacked together. As each tray carries a maximum of 10 bags, or 40 liters, of
milk, the uprights as in 22, 26 uprights together are able to support a weight
of
at least about 160 kilograms.
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[0025] Referring to Figure 3 in addition to Figure 2A, as will now be
appreciated by a person of ordinary skill in the art, trays may be stacked as
shown by reversing alternate trays and such that the uprights 22, 26 of the
lower tray 10' engage the underside 44 of the upper tray as in 10. In this
regard, the underside 44 of each tray comprises pairs of locating points as in
46 which receive the apex 48 of a respective upright as in 22, 26 therein.
Each of the first pair of uprights as in 22 butts against a respective outer
tab
as in 50 molded in the underside 44 and towards a lower outer edge 52 of the
tray being supported, and thereby prevents the tray being supported from
sliding on the first pair of uprights as in 22. Similarly, each of the second
pair
of uprights as in 26 butts snugly against a respective inner tab as in 54
molded in the underside 44 of the tray which thereby prevents the tray being
supported from sliding on the second pair of uprights as in 26.
[0026] Referring back to Figure 2A in addition to Figure 3, the tabs 50, 54
may
be tapered such that they better engage the tapered outer surface 40 of their
respective uprights as in 22, 26. In this manner the trays are stabilized
versus
one another thereby limiting shifting during transport or the like. Of note is
that, as contact with the underside 44 of the tray 10 is lost below the hollow
uprights as in 22, provision of the tabs 54 on the inside of the respective
supports as in 26 allows the uprights as in 26 to be positioned somewhat
farther apart while still maintaining contact between the apex as in 48 with
the
underside 44, thereby improving stability. In an alternative embodiment the
second pair of uprights as in 26 could be combined into one, with provision of
a notch towards the center of the apex of the unified support and a
corresponding notch engaging tab in the underside 44 of the tray 10 (all not
shown). With brief reference to Figure 1, additional gussets as in 56 can be
added to the uprights as in 22, 26 to improve strength.
[0027] Still referring to Figure 3, a series of indentations as in 58 are
typically
formed on the underside 44 of the tray 10 opposite the dividers (references
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16, 20 in Figure 1) during manufacture as the plastic cools and contracts.
Alternatively, additional ribbing may be added on the underside 44 to
increased strength.
[0028] Referring now to Figure 4A, in a first mode of operation trays as in 10
loaded with milk bags as in 60 are stacked in a 2 X 2 configuration and five
high on a standard commercial pallet 62 to form a supported stack 64. As
discussed above, in this manner a long edge of each of the trays as in 10, and
therefore those of the milk bags as in 60 is visible from the outside and
easily
recognizable. As the trays as in 10 are emptied, they are simply removed from
the top of the stack and placed to the side, typically by the customer given
their light weight. In this regard, the empty trays are light enough (for
example
a maximum of about 3.5 kilograms or 7-8 pounds) such that they can be
easily manipulated without the use of gloves or special tools.
[0029] Referring now to Figure 4B, in a second mode of operation, empty
trays as in 10 can be stacked as a nested stack 64 by reversing the
orientation of the trays, by aligning respectively the first pairs of uprights
as in
22 and the second pairs of uprights as in 26 and inserting the uprights 22, 26
of a lower tray into those of an upper tray an such that the lower surface of
the
upper tray rests upon the upper surface of the lower tray. In this manner, a
large number of empty trays can be compactly stacked to facilitate their
return
to the milk supplier or the like along with the standard commercial pallet 62.
[0030] Referring back to Figure 1, in an embodiment of the tray, for example
for use in transporting and displaying other food stuffs such as fresh produce
or the like, the dividers as in 16 and 20 may be modified, for example to
accommodate cartons or the like, or removed. In this regard, the selection of
the thickness of the plastic for use in manufacture of the support 12 will
typically be determined by a combination of the presence or absence of the
supporting dividers 16, 20 and the weight of the goods to be supported by the
=
tray.
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[0031] Referring now to Figure 4C, in a first such alternative embodiment the
trays as in 10 are adapted to receive a plurality of standard milk jugs 66.
Applicant notes that in conventional systems for the transport of such jugs,
subsequent layers of jugs are supported in large part by the jugs underneath.
One advantage of such a configuration as disclosed in Figure 4C, where the
jugs as in 66 do not support the upper layer, is that the materials used to
manufacture the jugs can be considerably thinner (up to 30%), thereby
reducing the costs of the jugs as well as reducing, as the jugs are typically
discarded after a single use, the amount of material which is discarded.
Additionally, jugs from the lower layers can be withdrawn without risk that
the
upper layer becomes unstable, or the like.
[0032] Similarly, with reference to Figures 4D and 4E, in a second and third
such alternative embodiment the trays as in 10 are adapted to receive
respectively a plurality of one (1) liter milk cartons as in 68 and a
plurality of
two (2) liter milk cartons as in 70. Again, as the upper layers of cartons 68,
70
do not rest on the lower layers, materials used to manufacture the cartons can
be thinner and less robust than a system where the cartons provide some of
the support for the upper layers, allowing for relatively inexpensive
materials
to be used.
[0033] With reference to Figure 4F, an additional advantage of the above is
that different products with different formats (bags, jugs and cartons) can be
easily mixed on a pallet 62, for example by providing several trays as in 10
of
each type of format on each pallet 62. Although in a first embodiment it is
foreseen that adapted for use with a different container format are able to
nest
with one another such that they can be easily stacked, in order to aid in
sorting the trays following use and to ensure their return to locations where
their respective format is used, in a second embodiment it is foreseen that
the
uprights of trays adapted for use with different container formats vary such
that the tray adapted for use with a first container format is unable to nest
with
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trays adapted for use with a different container format. This can be done, for
example by positioning the uprights such that they are slightly closer or
farther
apart, or by providing a keying system (for example different shaped uprights
or the like) such that the uprights of one tray are unable to nest within
those of
another tray unless they are of the same type. Color coding or the like could
also be provided to aid nested stacking of like trays.
[0034] Referring now to Figure 5, in a fourth alternative embodiment of the
tray 10 an additional pair of tapered hollow central supports as in 72 is
provided and the tray sized to accommodate twenty (20) standard milk bags
and for a 2 X 1 arrangement on a standard commercial pallet. Alternatively,
and with appropriate modification, the tray can be adapted to accommodate
either jugs or cartons. A first of the pair of central supports as in 72 is
positioned flush against the edge of the tray 10 while a second of the of the
pair of central supports as in 72 is offset from the tray such that when in a
stacked configuration in a first orientation the pair of central supports 72
of the
lower tray are engaged by the underside 44 of the upper tray (as are those of
the first pair of uprights 22 and the second pair of uprights 26). In a second
nested orientation, wherein the upper tray is rotated 180 degrees horizontally
to the lower tray, the pair of central uprights 72 of the lower tray are
inserted
into the pair of hollow central uprights 72 of the upper tray (again, as are
those of the first pair of uprights 22 and the second pair of uprights 26). In
this
orientation the upper surface of the lower tray is directly adjacent the
underside 44 of the upper tray.
[0035] Although the present invention has been described hereinabove by
way of specific embodiments thereof, it can be modified, without departing
from the spirit and nature of the subject invention as defined in the appended
claims.
